MTS 606 · PRODUCTION SUPPORT
How do you support Make to Stock when replenishment goes wrong?
Trace an excess, shortage, availability, production, or inventory symptom back through forecast/PIR demand, consumption, stock, open supply, production, and actual feedback. MTS must balance service and inventory—not merely complete production orders.
MTS CYCLE
Trace forecast into common stock and customer consumption
- 01Forecast / PIRSignal
- 02MRPNetting
- 03Planned supplyProposal
- 04ProductionBuild
- 05Common stockAvailability
- 06Customer demand & replanFeedback
SUPPORT LOOP
Diagnose both demand and inventory
State service and stock impact
Record material, plant, shortage or excess, customer impact, usable stock, open supply, and expected versus actual position.
Find the broken cycle step
Follow forecast/PIR → consumption → stock → MRP → production → receipt → common stock → customer demand.
Separate cause families
Forecast/PIR, consumption strategy, planning position, MRP/replenishment, production, fulfilment/ATP, inventory policy, and replanning exceptions have different owners.
Correct the owning layer
Correct demand, planning data, proposal, production, inventory, or integration; do not change safety stock or lot size for one exception.
Retest service and inventory
Validate PIR, consumption, stock, open supply, receipt, customer availability, remaining forecast, and next MRP result.
Monitor the balance
Use forecast bias, PIR governance, consumption review, MRP exceptions, stock ageing, shortage, and production-adherence controls.
FIRST MTS DECISION
Is the signal a forecast problem, a stock problem, or a real service risk?
MRP nets forecast and actual demand against common stock and receipts. A technically correct order can still be an undesirable replenishment decision.
Customer demand must consume forecast as designed or MRP may replenish both signals.
Finished stock may be unavailable because of plant, location, stock type, commitments, or ATP scope.
Excess and shortage are opposite outcomes of the same stocking policy; diagnose them together.
MTS DIAGNOSTIC PLAYBOOKS
Follow the symptom to the replenishment decision
01 · MRP did not create replenishment
Trace: forecast/PIR → stock → receipts → safety stock → net requirement → proposal. Confirm ERP sees a shortage.
02 · MRP created too much or too little supply
Trace: forecast → consumption → stock → open supply → safety and lot size → proposal. Check firmed or obsolete supply.
03 · Forecast is not consumed correctly
Trace: PIR → customer demand → strategy and consumption window → remaining PIR → MRP. Prevent duplicate replenishment.
04 · Produced stock is not available
Trace: production → confirmation → inspection → receipt → stock type → available stock. Production completion is not availability proof.
05 · Customer order cannot be fulfilled despite stock
Trace: demand → ATP → plant/location/stock type → commitments → confirmation. This crosses into O2C fulfilment.
06 · Inventory is too high or low
Trace: forecast and actual demand → consumption → replenishment → production → common stock. Test the result against stocking policy.
07 · Next MRP run still looks wrong
Trace: customer demand → consumption → actuals and receipt → stock → open supply → remaining PIR → MRP.
Use 101 for the stocking model; 202 for forecast, consumption, MRP, execution, fulfilment, inventory, and replanning controls; 303 for replenishment execution; and 404 for design proof.